Khumani Mining Application

1. Khumani Mining Application Johann Pienaar Director, Iritron (Pty) Ltd

2. Introduction Project Solution Agenda Benefits Considerations Summary

3. ASSMANG • ASSMANG shareholders – ASSORE and ARM • Iron Ore, Manganese and Chrome • ASSMANG sites – Beeshoek, Khumani, Blackrock, Cato Ridge, Dwarsrivier, Machadadorp • ASSMANG standardised on Wonderware Software in 2000

4. What is ASSMANG Khumani? On-Grade W&S Sample Tower Thickener HPGR Main Plant Paste Thickener Jig Plant Overland Conveyor Mine Area Primary&Secondary Crushing Off-Grade W&S ROM Stockpiles

5. KH-SUITEVOYAGER: Information Server Architecture SCADA Network A

6. Networks and Protocols • Separate IT, SCADA and PLC networks • GB single-mode fibre backbones • UPS and Generator backup • Redundancy Bruce HIPER-Ring Load-Out HIPER-Ring Plant HIPER-Ring

7. Galaxy: Size Does Matter! • Khumani Phase 1 (September 2008): • 165 Templates • 6,746 Object Instances • 48,358 IO • 33,636 Historised Tags • Khumani Phase 2 (2011): • 200 Templates • 13,000 Object Instances • 90,000 IO • 65,000 Historised Tags

8. IO Servers • IO Servers: • TopServer for ContolLogix PLCs • DASMBTCP for Online Analysers • Two sets of Redundant Application Servers: • Dual CPUs • 2.0 GHz Core 2 Duo • 2GB of RAM • CPU Utilisation: • AOS1 – Max 24% • AOS2 – Max 15%

9. Introduction Project Solution Agenda Benefits Considerations Summary

10. System Platform 3.0 Approach • Naming Conventions • Modelling and Standards • Deployment Considerations • Archestra Graphics • Automatic Tag Linking • Instantiating Objects • Addressing Software Problems

11. Naming Conventions • Do Your Engineering Upfront: • Naming Specification • Functional Specification • Detail Design Document • Thin-slice Archestra templates • P&ID derived naming convention was used for all object instances: <site>_<area>_<equip>_<instr>_<signal> Example: 90_DS50_PU15_FIT01_FI • Define Template, Attribute, Script and Graphics naming conventions

12. Modelling and Standards Site • Wonderware Best Practices Guideline • Wonderware System Platform Checklist • S95 Standards Enterprise Sub-Area Area Process Cell

13. Deployment • “Fine Tuning and Optimisation of WW System platform” • Utilise Archestra’s multi-threading capabilities on multi-CPU servers: • Multiple application engines • Prime number scan intervals for scan groups

14. Graphics Approach Graphic building blocks were created in the Graphics Toolbox The building blocks were grouped in Toolsets Graphic building blocks were used to create Object Graphics SCADA mimics were created as Local Graphics in the Area instances No graphics were created in Intouch - Each Intouch page contains a single Archestra symbol

15. Graphics Toolbox • Create all Graphics Symbol building blocks in the Graphics Toolbox • Graphic Symbols grouped in Graphic Toolsets • Adhered to best practises: • Used only LOCAL Custom Properties • Made internal properties private • Be aware of limited error checking

16. Graphics Toolbox Graphic Toolsets Graphic Building Block Use Custom Properties

17. Object Graphics Template Graphics

18. Object Graphics Graphic Building Blocks Link Object Attributes

19. Mimic Graphics Area Instance Area Model SCADA Mimics

20. Automatic Tag Linking Automatic Tag Linking is one of the most powerful features of Archestra: Standardised on tag based A-B ControlLogix PLCs Implemented standard blocks in PLC Rigidly enforced our chosen tag naming convention Linked to PLC tags via scripting

21. Automatic Tag Linking

22. Automatic Tag Linking

23. Instantiating Objects The fastest method of creating multiple instances - use the CSV Export and Import Object functionality Create, then Export an example instance, copy/paste the new instances and Import Only keep the necessary columns Use Excel 2007 or later

24. Zapping Bugs We were one of the first companies to start a System Platform 3.0 project: ASSMANG Cato Ridge – Started development on Beta version (July 2007) ASSMANG Khumani - Started development on Gold version (Aug 2007) Identified NUMEROUS bugs Progressed through Patch 1, Patch 2, Patch 3, SP1, numerous Hot-fixes and finally SP2!

25. Bugs

26. More Bugs Copy Paste chaos! Archestra Graphics: >10min to open! Managed Intouch Application: >1hr to open! Duplicate ID’s

27. Denial! • During the first 4-months of the project: • We assumed that the issues were being addressed • We did not realize that we were the first to experience the problems • We blamed most of it on finger trouble and network problems • We became very creative at finding workarounds • We reported nothing!

28. Zapping the Bugs! • From Feb 2008 to Sept 2008: • We started logging ALL issues - we logged more than 39 issues • The severity of the issues ranged from terminal to minor irritation • More than 25 Hot fixes, Patches, Service Packs and Utilities have since been issued by Wonderware to address these problems • SP1 – We were the 1st and only to install SP1 • Support staff from Wonderware EMEA and Wonderware SA flew out to site on numerous occasions to investigate the issues • We arranged weekly WebEx teleconferences with Wonderware EMEA and Wonderware USA

29. Reporting Procedure • Reporting chain: SI/Client -> Wonderware SA -> Wonderware EMEA -> Wonderware USA • Phone Wonderware support (0861 WONDER) to determine if this is a known issue • Send supporting e-mails to support@wonderware.co.za and not to individuals • To fast-track the problem, one has to provide Wonderware with a RECIPE to replicate the problem

30. Reporting Procedure Recipe: An in-depth description of the problem Software versions - Wonderware and Microsoft Wonderware SMC log-files (.aaLGX) from the View Node, Galaxy and AOS Microsoft log-files (.evt) from the Microsoft Event Viewer – Application, Security an System Screen-captures (.jpg) illustrating the problem Galaxy Backup (.cab) or Object Export (.aaPKG) Wonderware SA can only escalate the problem to Wonderware EMEA once they have also been able to replicate the problem

31. Reporting Procedure KEEP YOUR COOL – We are all in the same boat! Before a Hot-fix can be issued to an SI or End-User, a signed Hot-fix agreement has to be signed

32. The End Result After SP2: Archestra Graphics: <10sec to open Managed Intouch Application: <30sec to open All mayor bugs have been zapped! The only outstanding issues are nice-to-haves, all of which I still want!

33. Introduction Project Solution Agenda Benefits Considerations Summary

34. Benefits • Initial development time took longer than expected due to: • The bugs in the software • The P&ID’s were never frozen • The PLC developers made drastic changes in their code until very late in the project • Inexperience

35. Benefits However, for phase 2 of the project, the picture is completely different: Development time will be drastically reduced FAT Testing and Commission time will be minimal No scalability constraints

36. Introduction Project Solution Agenda Benefits Considerations Summary

37. Considerations The Galaxy Repository is a critical component. Have an off-line system available for tests and as backup Communicate with Wonderware – bugs don’t fix themselves! TRAINING, TRAINING, TRAINING! Higher skills level required for Archestra than for Intouch Do your Engineering upfront, BEFORE you begin with your Archestra development

38. Considerations • Manage Archestra biggest strength/weakness – it’s flexibility • Draw up a System Checklist for setting up all computers in the system • MAKE REGULAR OFF-SITE BACKUPS • Be aware of the risks when developing in a new version of any software • Make use of VPN Dial-In and Microsoft Remote Desktop

39. Introduction Project Solution Agenda Benefits Considerations Summary

40. Summary • Communication and Teamwork are critical • All software bugs can be overcome! • We have a happy client • The Archestra system works brilliantly • We are looking forward to phase-2 of the project!

41. Questions Questions?